One-Piece Shirt Collar Structure and Methods of Use

ABSTRACT

The present invention provides a one-piece shirt collar structure and method of use for keeping a shirt collar firm and in place, and to ensure that the shirt collar lies flat and correctly on the front of a shirt. The shirt collar structure is firm, yet flexible and breathable to allow ventilation through the shirt collar. The shirt collar structure is comprised of a four-sided, substantially flat structure comprised of a flexible material having an interior therein, wherein the structure has a first and second end and a first and second side; the first side being convexly-shaped and the second side being concavely-shaped, and wherein the interior at the first and second ends contains a rigid material therein and the remainder of the interior contains a mesh material therein.

FIELD OF THE INVENTION

The present invention relates to collar stays for shirt collars and, in particular, to a one piece, breathable, shirt collar structure for maintaining a shirt collar in place.

BACKGROUND OF THE INVENTION

Collar stays, also called “collar tabs” or “collar stiffeners,” are used inside special pockets on the underside of shirt collars in order to keep the shirt collar in place by adding weight and crispness to an otherwise light and flexible piece of fabric. Collar stays can be made from almost any type of material, such a heavyweight paper, baleen (whale's'tooth), horn, sterling silver, mother of pearl, and other precious metals, but these materials are not commonly available. More commonly, collar stays are made of flat pieces of plastic or metal, which are either removable or sewn-in. Sewn-in collar stays are almost always made from a thin, flexible plastic, as they try to balance giving a rigid look to the collar without damaging it in the wash. The disadvantage of using thin, flexible plastic collar stays is that they are light and flimsy and shirt collars oftentimes do not lay correctly.

Metal collar stays are made from stainless steel, brass and even gold. The disadvantage of these collar stays is that they are quite costly, ranging from about $25.00 for a set of stainless-steel collar stays to about $600.00 for a set of gold collar stays.

There exists a need, therefore, for a collar stay that keeps a collar firm, in place, and that lays correctly on the front of a shirt.

SUMMARY OF THE INVENTION

The present invention fulfills this need by providing a firm, yet flexible and breathable, one-piece shirt collar structure and method of use that is placed within a shirt collar to keep the shirt collar firm, in place and lying correctly on the front of a shirt.

In an aspect of the invention, there is provided a one-piece shirt collar structure comprised of a four-sided, substantially flat structure comprised of a flexible material which defines an interior therein. The substantially one-piece flat structure has a first end, a second end, a first side and a second side. The first side may be convexly-shaped and the second side may be concavely-shaped. The interior at the first and second ends contains a rigid material therein, and the remainder of the interior contains a mesh material therein.

In another aspect of the invention, there is provided a method of maintaining firmness of a shirt collar and keeping the shirt collar in place by inserting the one-piece shirt collar structure inside the shirt collar. The method comprises opening one end of a shirt collar to allow access to the interior of the shirt collar; placing the first end of the shirt collar structure described above into the interior of the one end of the shirt collar and moving the first end of the shirt collar structure through the interior of the shirt collar until the first end of the shirt collar structure reaches the other end of the shirt collar; and closing the one end of the shirt collar.

BRIEF DESCRIPTION OF THE DRAWINGS

A fuller understanding of the invention can be gained from the following description when read in conjunction with the accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, which illustrate some, but not the only and exclusive, examples of embodiments of the invention and, as such, the figures disclosed herein are to be considered illustrative rather than limiting. In the drawings:

FIG. 1 is a top view of the one-piece shirt collar structure in accordance with an embodiment of the invention; and

FIG. 2 shows the one-piece shirt collar structure placed within a shirt collar interior in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, the one-piece shirt collar structure of the invention is comprised of a four-sided, substantially flat structure 10 comprised of a flexible material 20 defining an interior therein 24. The substantially flat structure has a first end 12, a second end 14, a first side 16 and a second side 18. The first side 16 may be convexly-shaped and the second side 18 may be concavely-shaped. The interior 24 at the first and second ends 12, 14 contains a rigid material therein 22, 22′, and the remainder of the interior 24 contains a mesh material 25 therein. In an embodiment, the rigid material 22, 22′ is rectangular in shape.

The rigid material 22, 22′ may be manufactured from any suitable non-flexible plastic including, without limitation, a high density polyethylene (HDPE) film, such as, for example, moisture-resistant HPDE manufactured by McMaster-Carr. In an embodiment, the thickness of the rigid material 22, 22′ ranges from about 0.02 inches to about 0.04 inches. In another embodiment, the thickness of the rigid material 22, 22′ is about 0.03 inches.

The mesh material 25 may be manufactured from any suitable flexible plastic including, without limitation, polybutylene terephthalate or polypropylene, so long as it contains small apertures in the mesh and is lightweight, for example, Product No. XN8500 from Industrial Netting. In an embodiment, the thickness of the flexible material ranges from about 0.02 inches to about 0.04 inches. In another embodiment, the thickness of the rigid material is about 0.02 inches.

The flexible material 20 may be manufactured from any suitable material including, without limitation, ribbon binding manufactured by Berwick Grosgrain. In an embodiment, the ribbon binding is about 0.5 inches to about 2.0 inches wide. In another embodiment, the ribbon binding is about 1.0 inches wide.

As shown in FIG. 2, the one-piece shirt collar structure 10 is located within the interior of a shirt collar, in which the first and second ends of the shirt collar structure are located near the ends, or openings, of the shirt collar. The invention contemplates that the rectangular shape of the rigid material 22, 22′ matches the rectangular shape of the shirt collar so that the ends of the shirt collar are fixed in place and lie flatly on the front of the shirt.

In use, the one-piece shirt collar structure 10 described above may be placed into a shirt collar by opening one of the ends of a shirt collar. The first end of the shirt collar structure then is placed into the interior of one of the ends of the shirt collar and is moved through the shirt collar until the first end of the shirt collar structure reaches the other end of the shirt collar. The one end of the shirt collar that was opened then is closed. The shirt collar structure may be secured within the interior of the shirt collar with the use of a nylon or polyester hook and loop fastener, such as, without limitation, Velcro. Those skilled in the art would understand how to use a hook and loop fastener to secure the shirt collar structure of the invention to the interior of a shirt collar. Alternatively, the shirt collar structure may be secured within the interior of the shirt collar by sewing the shirt collar structure to the collar during assembly of the shirt collar. In an embodiment, the shirt collar structure is sewn, i.e., tacked, to the shirt collar in a plurality of places. In another embodiment, the shirt collar structure is sewn in three places: at the ends of the shirt collar and at the back of the shirt collar.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications that are within the spirit and scope of the invention, as defined by the appended claims. 

What is claimed is:
 1. A one-piece shirt collar structure, comprising a four-sided, substantially flat structure comprised of a flexible material defining an interior therein, said substantially flat structure having a first end, a second end, a first side and a second side; said first side being convexly-shaped and said second side being concavely-shaped; said interior at the first and second ends containing a rigid material therein; and remainder of said interior containing a mesh material therein.
 2. The one-piece shirt collar structure of claim 1, wherein the rigid material is comprised of a rigid plastic.
 3. The one-piece shirt collar structure of claim 2, wherein the rigid plastic is a high density polyethylene film.
 4. The one-piece shirt collar structure of claim 2, wherein the thickness of the rigid material ranges from about 0.02 inches to about 0.04 inches.
 5. The one-piece shirt collar structure of claim 1, wherein the mesh material is comprised of a flexible plastic.
 6. The shirt collar structure of claim 5, wherein the flexible plastic is a polybutylene terephthalate or a polypropylene.
 7. The one-piece shirt collar structure of claim 1, wherein the flexible material is comprised of a ribbon binding.
 8. A method of maintaining the shape of ends of a shirt collar, said method comprising: interior one end of a shirt collar to allow access to interior of the shirt collar; placing the first end of the one-piece shirt collar structure of claim 1 in the interior of the one end of the shirt collar and moving the first end of the shirt collar structure through the interior of the shirt collar until the first end of the one-piece shirt collar structure reaches the other end of the shirt collar; and closing the one end of the shirt collar.
 9. A method of claim 8, wherein the shirt collar structure is secured within the interior of the shirt collar with a hook and loop fastener.
 10. A method of claim 8, wherein the shirt collar structure is secured within the interior of the shirt collar by sewing the shirt collar structure. 